aluminum wire vs copper wire for electromagnets

[logos]

does anybody have any experience using aluminum wire to make electromagnets?

what are the differences in regards to regular copper wire?

[Savvypro]

Use of aluminium wire is not a good idea as it can get very hot and cause fires.

[Iotayodi]

You can use aluminum but you need to stay within its ampacity rating. The same size copper wire can handle more amps. You would need a #10 aluminum wire to handle 20 amps compared to a #12 copper which handles 20 amps. A #12 aluminum can only handle 15 amps.

Ampacity Charts

[Ernst]

I have been using Al-wire in some coils for transformers. It is a LOT cheaper, its conductance is slightly less (2.8 vs 1.7 *10^-8 Ohm.meter, I thought), it conducts heat better and it weighs much less.

They are using it in old fashioned welding transformers (the 50/60 Hz ones). I have seen it being used for 7-24 KW transformers. So I guess its OK for that application.
For electromagnets, I honestly don't know, but my guess would be that it would be safe to use.

Ernst.

[barbosi]

Aluminum or copper, make sure you know How to Make Proper Wiring Connections

[Michelinho]

Hi all,

I have found aluminum coils in micro-wave HV transfo so I guess that makes the Al wire safe for domestic use. Just follow the rating of your particular wire size.

Take care,

Michel